Process of and apparatus for making cement clinker.



G. ELLIS. PROCESS or AND "APPARATUS POP. MAKING CEMENT GLINKER.

APPLICATION FILED MAY 23. 1908.

Patented Jan. 19, 1909.

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fami/a ZZP v6 .79 M@- wt l G. ELLIS. PRGESS 0F AND APPARATUS FOR MAKINGCEMENT CLINKBR.

AYPLIGATION FILED MAY 23, 1908.

G9 fi Patented. Jan. 19, 1909. z SHEETS-SHEET z.

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, different, the first requiringfa large volume u-'NITED STATES' PATENTOrrion.

OARLETN ELLIS, or LARciiMoN-r, 'una YORK, ASSIGNORITO ELLIS-FOSTERCOMPANY, A

- CORPORATION orNEw JERSEY.

m-toonss 'or AND APPARATUS FOR MAKING GEMENTCLINKER.

Specification of I ietters Petent Patented Jen. i9, 1909'.

Appiicatimmea my 23, 190e.v semi No. 434,554.

To all whom 'it may concern:

Be it known that I, CARLETON ELLis, a citizen: of the United States,residing at Larclnnont, in the coun-ty of lllestcliester and State of'New York, have invented certain new and useful Iiiipi'ovements inProcesses of and: Apparatus forlllaking CementA Clinlter, of which thefollowing is'a speeifieation. y. 1

This invention relates to processes of ad apparatusfor ymaking cementelinker; and

comprises a methodin which cement material is first calcined by a'port-ion of the waste gases from a cliiik'ering hearth and is theirclinkered on such hearth, the residue of the gases from suoli hearthbeing regenerative-.ly employed to maintain the temperature ofAsuchhearth; and it also comprises certain organizations tof apparatususeful-in the deseribed'met-hod; all, as more fully hereinafter set.forth and as claimed.-

In the customary methods of making cement cliriker in this country, thepowdered cement. material is fed forward through a rotary inclinedcylinder against al current of flame and flame gases going upwardthrough the kiln-cylinder and derived from a lllame plume of powderedcoal burning in aerial suspension 'in the mouth of said cylinder. Thisflame hasa double function: in

its immediate vicinity itvfaffords a sullicientdegree of temperature tocause the ealeined cement material to frit and sinter to form clinkei'while the hot flame gases going beyond calcined sueliJiiaterial;l thatis,'deprive its limestone component of carbon*v dioxid and convert itinto lime which, in the clinkering zone, combines with the claycomponent to forni clinker. The requirements of the ealcining andclmkering operations are q'uite 4tain with other fuels than powderedcoal in aerial suspension; and ine-.grindin'g'coal isl somewhatexpeiisive. Arnd inv producing 'sneli a' coal flame, it is necessary to'provide for a copious influx of air, quick and intenseeolrnbu'stion'only takingplae'e 1n the presence of anexeess of air, an

suelijl material.

Ordinary rotary kiln' of (i or 7 feet. internal since allz the draft" islthrough the kilnitselii, there is a violent rush of llame gases and airthrough the kiln which tends to pick up in uch dust. The. finelypowdered cement mixture in normal calcining 'evolves oai-bon dioxidvthroughout its mass, andv this gas evolution Combined with the greatelra'ft of the" kiln causes the stated dusting. Fo'i' another thing, theintensely hot gases coming from the clinkering flame -tend tn hug theroof of the kiln, spaced away' from the stream ofi'cenientinaterialflowing' down its base by a; lay

of cooler 'air and of carbon dioXid evolvelbya` It is for thisreasonthat-the diameteris usually made about feet; long for beyond 60feet in; kilns of the usual type the superimposed' hot as stratum nolonger through the underlying coolerf ,ciii'ients to the cementmaterial. But the nio'st seriousdisadvantage isthat witlithe singlekiln-thc two operations are made interdependent since the rate Offlow ofmaterial through the` calcining zone'niust 'be the same as the rate offlow through the olinkering zone; the maf tei-iai must travel in'a'c,ontinuous`stream through both. The requirements of the twocommunicates a use ul ainougt of heat.l

Operations are so diverse that `they should" i not as 'a matter of goodpractice be so linked together. l

In the present invention, I have devised means for and a method of,performing the two operationsjindependently and eaeh'ilm-" der theconditions best adapted thereto while the present -practice of using asingle source of heat; rl-his source Ot heat 1s preferably gas, such asproducer gas.

4'while it has frequently been suggested foi*- vat the sametiine'ietaining the' advantage of'.

Producer gas,

firing cement kilns islittle used in practice since it.. does not givetlieiiecessary amount of '-lieat forclinkeringfunless its-flainei'teni#peinture be stepped up in'so'me manner; as by the use oflregenerat'orsfor4 rec'npeiatOrs-neitlier of which hoveveispracticablefor use with the Ordiijiary'single rotaryA kiln because of theinordinate` dusting which takes place in kiln and-.Which causes the,

aid of astream of hot.waste gases substan-- .will

in connection with regenerators Aor-recnperators, and they are so usedin the present invention. While powdered coal, oil or rich gas may alsobe employed,-and with advantage in some cases, I regard my invention asparticularly ada ted for use with the cheap) formsof pro ucer gas andsuch gas In the present invention, the two operations ofcalcining andclinkering are more or less segregated, each being performed 1naplpa'ratus particularly adapted thereto. The ca cining I perform in arotary kiln with the tially filling the whole cylinder and thereforecontacting with the stream of cement, material instead of being-s acedaway there-5 from as in theordinary ki n', developingthe llame yieldingthe wastegases elsewhere than in this kiln so that there will be nonecessity' 'for instituting draft conditions and conseuentstratification of gases therein. 'Under t ese conditions a' maximumeconomy of heat in the 'calciner may-be obtained and an eiiicientcalcination as well. `In some measure, the sheer temperature requiredfor calcnation is reciprocally related tothe 'perc'entage of' carbondioxid in thel mass bathing the matcrialbeing'calcine so that in theordinary operation where the evolvedV carbon dioxid tends -to ilowforward over'the cement material as a discrete stream uder' lying the'hot flame gas stratum, as in thev stratified gas currents' going through'the ordinary kiln, calcination conditions are not as favorable as inthe present method where evolved dioXid is at oncediluted -in the hotgas mass filling thekiln and bathing 'the Y solid cement material.

The hot calcines, free or substantially free, of carbon dioxid, Ideliver'upon a .hearth where such calc'ines are raised to a clinkeringheat, the hearth chamber being .heated by any suitable'- fuel. Wastegases. from the hearth chamber though preferably but -a' portion of suchgases," are assed upward through the rotary kiln to e ect calcin'ationin the manner described. It will be noted that in the describedoperation, I make calcinationl and' clinkering Wholly independentoperations though retaining the advantage of the ordinary practice ofusine but a single source of heat. There is, ofcourse, no necessary-relation'between the speed of feed of materials through the rotary kilnand the ,length of time thatjnaterials remain on the I.' Aiarnetemperatures. Substantially all the e more specifically recitedhereinafter.

generatorsor recuperators can be used in connection withthe clinkeringchamber.

In using producer gas, for chemical reasons, the volume of air necessaryfor bnrn. ing the gas will be'but hall" the volume of the resultantproducts of combustion. There- 'fore but half of such products ofcombustion so connected that the calcines are 'delivered directly uponthe hearth, while such portionA of the products of combustion as is not'needed 1n the regenerators passes directly up the calciner. -By suitableregulation of dampers in the stacks respectively connected with theregenerators and with the calcining kiln the fractions of waste gasespassingl the hearth chamber and calcining kiln being A either way can beregulated and controlled.

No flame being-.produced in the calcining kiln, there is nostratification of gases therein nor isthere a violent rush of gasestherethrough "so that dusting losses are minimized. A The hearth itselfmay be of any convenient ty e. If .it be desired to push the elinkering'iieat up to the point of fusing the clinkered material, such fusedmaterial may be tapped olf the hearth into a suitable con .duit andtherecooled or quenched. Or, if the materialbe merely siutered or fritted, asin the ordinary practice, it may be withdrawn from time to time bysuitabletools or it may be discharged by rocking'or other- -wisemanipulating the hearth i'n well understood ways. l

'In the accompanying illustra-tion I have shown, more or lessdiagrammatically, certain types of apparatus of the many adapted to beemployed in the described-process. y

In this showing: Figure l is a vertical Atransversesection on line y-g/of Fig. 2, showing hearth and| gas and air ports; 'F.g.

2 is a vertical longitudinal lsectionof Fig. l;

- hearth is denoted by l and the inclosing health chamber wall by 2.Entering the chamber at either side are ports for .alr and gas. Theports'at the left of the hearth are 'respectively marked 8 and 4, andeach communicates with a regenerator check erwork, that for the airbeing marked 5 and that for the gas 6. Duct 7 servesalternately In Fig.v1,:tfhe

`for-introduction of air and removal of wastev ases duct 8 alternatelfor introduction of gas and removal of waste gases. The ar- -and Fi 3'isa'planview ,of an alternative ,form o hearth.

- moving this plug 'the fused material'may. ghe tapped oit at.intervals.

eioaei -rangement at .the right of the .hearth is exactly the same,p'orts 9 and 10 being for air -away to a stack (not shown). -A pair of.valves 19 and 20, of familiar type, serve to control the circulationto, throi'ig'h and from the hearth chamber. Element 21 is the end of thecalcining kiln.

Referring now to View at right anclesto that of Fig. 1, 22 is a movablehood c osing the end'of'the hearth chamber 4and provided with .door 23.The hearth, which'is, as here shown, of arocking type, is mounted onroller 2 4 at the rear end and cam 25 at the front, whereby it may begiven a rocking motion or may be-adju'sted at di'erent angles ofinclina-tion. Clinker is discharged from the front end into closedclinker pit `26 having an adjustable door 27 and a .pipe connection 28for introducing quenching' water or steam. The door serves to controlthe ingress of air into the clinkerpit. lheacalcining kiln, which is ofthe familiar open-ended cylindrical 'inclinedrotary type at its upperend enters'the stat-ionary housing 29 provided With dust door 30 andstack 31, damperedat 32.. Cement inaterial is fed from hopper 33 bymeans of conveyer 34 to chute 35 which discharges it Within thecalcining kiln. In Fig. 3 is shownaa plan view of a hearth suitable foruse when it is desired to fuse.

the clinkered material; As shown, this hearth has an inclosing dam 36'which at '37 is provided with an orifice closed by a plug of readilyremovable material so that by re The operation of the heating meansshown m Flg. 1 is obvious. As shown, valve 19 l set so that air may passthrough 7, 6 and 4 into the hearth chamber, burning gas from 3, While'products ofcombustion may go to exit through 9, 1'0, 12, 1I, 13 14 andI7. -Valve 20 is shown so set that gas may .pass from 16 through 8, fand3 to be burned as just described While products of combust1on `may passaway from the furnace chamber just as described. lith this setting,theiiame burns at the left of the hearth chamber While when the valves arereversed the flame will lmrirat the right. A11-adjustable amount ofintensely heated auxiliary air ascends from the clinkerpit.

lVith this apparatus, the. temperature of the fiame sweeping across thehearth may be raised to almost any temperature desired and clinkeringeasily and quickly effected. If desired, the clinkerfmay be `fused Fig.2 AWhich shows a and tappgd ofiI 'the hearth as liquid, or it may beproduced in the ordinary smtered masses. In the latter event, the hearthmay be Vrocked to promote the 'passage ofthe clinker forward vto theclinke'r pit, or the. clinker may be raked forward. by suitable tools;lVhatevei" the rate' otl feed and of treatment ofmaterial in the rotarycalcin ers-:the ca-lcines may obviously be allowed to remain on thehearth for as'long or short a time'as may be desirable.- VVith aregenerated gas flame produced as describcchhowever, the time requiredfor clinkering is relatively very short, the temperature being high sothat a. hearth of moderate size may deal with 'the calcines from severalrotary calcining` kilns.

Clinkering being an operation consuming but littleheat thoughrequiring,r an intense temperature, Whilel it may even develop someheat,and the heat units developed in the clinkering chamberbeing largelyintercepted from thelgases going to'waste through the regenerators andreturned to such chamber,` a large part offthe total heat unitsdeveloped in the hearth chamber therefore in4 practice are delivered tothe fraction ofthe Waste gases. which go through the .calcner. In vthecalciner the consumption of heat 'is large but by presentingthe Igasesas hot as Vare the Waste gases from thel regenerated flame of theclinkering hearth calcination is ,quickly effected. The gases enteringthe calciner at sohigh a temperature, the curve of evolution of carbondioxid is quite sharp so that'a relatively short ealciner may beemployed While at the same time absorption ot' heat maybe quiteeffective, the gases finally passing' away relatively cool. The burninggases being effectively mixed and their combustion being, practicallycompleted in the hearth chamber, such portion of Waste Lases as is drawnoff through the calciuer is not stratified and henceA is alleffectivefor calc ination. With proper reguthe regenerators and in thatof the calciuing kiln, a comparatively slo\v, v regular movement ofgases maybe produced through dusting and contributing to effectiveutilization of heat units therein. Since the air drawn from the clinkerpit m'ay'be as hot as that from the regenerators, an equivalent amountofthe products of combustion from the 'hearth chamber may be divertedthrough the calciner. Any steam which may be formed in quenching clinkerascends with the hot 'airf and proves useful in 4the calciner, the.presence of Water vapor much 'facilit-at 'ing calci'nation. y

Theraw 'material employed in the apparatus may be any of the materialscustomarily employed for making cement clinker lation of danipers inthewaste. Q;as exit ofl the calciner, thereby at once preventingl 'cementrock, etc.l

such as clay -and limestone, naturally or artificially mixed, mixtures'of slag and lime,

The producer gas may 5 duced `from the producer without going throughA agenerator as such gas is customarily very het and sufiiciently so to beable to ailord, with/ regenerated fair, the

flame temperatures' necessary. In so doing,

the regenerator chambersmay be somewhat smaller and afurther quantity ofthe flame gases may be diverted up the calcining kiln. In regenerativelyheating the' gas, recuper- 'ators may be employed beyond the regeneratorto aid in heating the air.

What Il claim is 1. The clinker which comprises the clinkering. ofcalcined cement material by a flame burning with regeneratively heatedair, diversion' of -into regenerative heaters for air for said flame andcalcination of cement material bythe residue of said flame gases.

2. The process of producing 'cement clinker which comprises theclinkering of by the residue of said flame gases.

3. The process `of producing cement calcined cement material b a flame'of hot producer gas burning wit regeneratively -heated air, diversionof a portion of the flame gases from such flame into regenerativeheaters for said flame, and calcination of cement material by theresidue of said flame gases.

4. Thel process lof 'producing clinker which comprises producing atravelmg stream of cement material, calcin'ation of such stream byanopposed current of intensely heated flame 'gases from such flame comingfroma regeneratively fed clinkermg flame drawing heat from anotherportion-of such flame gases, delivering the calcined material on ahearth in roximity to such llame, maintaining the ca cined mate- A rialon such hearth until clinkering is ef- .fected and finally withdrawingthe clinkered material.

5. The process of producing cement clinkerwhi'ch comprises calciningcement material in a rotary inclined kiln by a body of intensely heatedflame gases, delivering the' calcines into proximity 'of aregeneraehearth chamber and there clinifering the same, diverting a portion ofthiv naine gases 1 hearth chamber and abstractmg the residue from suchflame into the calcining kiln and passing the residue of said-flamegasesinto regenerators .supplying said flame.

be directly i'n'troprocessof. producing cement a vportion of the llamegases from-such flame clinker which comprises 'the clinkering of.

cement` tively supplied flame burning in a stationaryE 6. In themanufacture of cement clinker, the vprocess which comprises clinkermgcal- `cined cement material on a stationary hearth by a regenerativelysupplied gas fiame,and calcining raw cementmaterials by a divertedportion of the hot flame gases from the same ame, thecalcines oproducedbeing supy plied to said hearth.

7. The process of producing cement clinker which comprises clinkeringcalcines on a hearth by a flame burning thereover, diverting a portionof the hot flame gases to supply recovered heat .to said flame,diverting the residue of said gases. in a Well-mixed state to a separatecalcining kiln, and supplyinor calcines from said kiln to said hearth.

-8. hearth chamber and a-calcining kiln deliv- 'eringand opening intosuch hearth cham` ber, means for producing a regeneratively supplied'amein such hearth chamber, regenerators for feeding such ame and means fordividing the hot flame waste gases "between such calcining kiln and suchregenerators.

9. A clinker making plant comprising a stationary hearth chamber and arotary calclinker making plant comprising a .cinino'f kiln supplyingcalcines thereto and withdrawing a portion of flame, gases therefrom,and means for heating.,-said hearth chamber, said means comprising heatrecovering means utilizing the residue of said flame gases and flameproducing means utilizing the recovered heat.

10. A clinker making plantcomprising a hearth chamber, flame producingmeans for f such chamber, heat recovering means in communication withsuch flame producing means and such chamber, a calcining kilndeliveringcalcines to said hearth chamber and in open communication therewith, andregu'- lable means for sending adjusted proportions of hot 4flame wastegases through such ealcining kiln and such' heat recovering means.`

11. A clinker making plant comprising a hearth chamber, flame producingmeans for i such chamber, ,heat recovermg means in communicati on withsuch flame producing means and such chamber a rotary inclined calciningkiln delivering calcines to said hearth chamber and in opencommunication therewith, and regulable means for sending adjustedproportions of hot flame waste gases through -such calcining kilnandsuch heat recoverin means.

A 12. A c inker making plant comprising a hearth chamber, means forproducinga gas ame therein, regenerative means abstractving a portion ofthe hot gases from the flame and returning their heat to the chamber and'a calcining kiln delivering calcines to the of the hot tlame gasestherefrom.

13. clinker making plant comprising a -ing into the `furnace chamber ovehearth chamber, .means for producinv a gas ame therein, re enerativemeans a stractz inga portion ro the hot gases from' the ai'ne and'returning their heat to the chamher, and a rotary inclined calcning kilndelivering calcines to the hearth chamber and abstracting the residueofthehot flame gases therero '.p' 1f.'

14. A clinker making ,plant comprising a reversing hearth-furnaceprovided viith'heat-v n regenerating devices, a rotary. inclined set todischar e calcines upon the hearth 'of said furnace, ame produclng'means1n said furnace" and means for* causinghotiiame gases from saidameproducing 'means lto kiln for permittingthe liow of a regulatedupandthrough the'kiln,

', 16. A elinker making plant comprising a' `reversing;gas-iired furnaceprovided with aff.' hearth" 'and with regenerators onoppositetion;Wastefgas removing means for said re-l into the hearth chamber and.discharging 35 upon, the hearth, vand Waste gasremovng" means at theupper end of the kiln' for "removing a portion of the flame gases"through the kiln; f'

in the presence of two, Witnesseg' A i CAnLnToNELLS Witnesses:

, j "l BISDELLA- M. linnrsfig '-1 j NATHANIEL L. FOSTER.

amount ci hot flame gases from said flame 25 Sj'des'co'imunicating withthe hearth charli- .3Q- ber-adapted :to produce a regenerativelyav'heated gas Hanne over said hearth in alterna ""e'nerators, 'a rotary'inclined kiln opening' In testimony whereof I aiX' my signature 40

